Manifold system of low pressure suction and high pressure discharge

ABSTRACT

The present invention discloses a manifold system of low pressure suction and high pressure discharge, which includes a low pressure manifold, a high pressure manifold and a plunger pump. The low pressure manifold transports media into the hydraulic end of the plunger pump. The hydraulic end of the plunger pump is provided with two discharging ports, which are connected into the high pressure manifold. The present invention has the following beneficial effects: the five-cylinder plunger pump at 5000 HP or above ensures the high pressure and large displacement power source for the fracturing equipment. The dual discharge form of the five-cylinder plunger pump achieves the smooth discharge of liquid from the five-cylinder plunger pump and prevents sand from accumulating within the low pressure manifold, meanwhile ensures the large displacement of the fracturing equipment. The low pressure manifold employs a large drift diameter manifold of 10 inches, with the double suction of an U-type tube to realize sufficient large displacement liquid supply from the five-cylinder plunger pump.

TECHNICAL FIELD

The present invention relates to the technical field of plunger pump fracturing, and specifically to a manifold system of low pressure suction and high pressure discharge.

BACKGROUND

With the continuous development of oil and gas fields, the working conditions are becoming more harsh, requiring high pressure and large displacement operations to meet the mining demands. However, if a single fracturing equipment would meet the output with high pressure and large displacement, in addition to enough output power from itself, the low pressure manifold is also required to import sufficient fracturing fluid, and the high pressure manifold is required to export fracturing fluid with high pressure and large displacement.

Especially in the non-conventional oil and gas operations—shale gas operations, the working conditions are very harsh, in addition to large displacement and high pressure operations, long-time continuous operations are also required, and the operations are becoming more and more frequent, thus the requirements on fracturing equipment become increasingly higher. However, for the low pressure manifold and the high pressure manifold, which are key components for ensuring large displacement and high pressure for fracturing equipment, higher requirements have been proposed accordingly to satisfy this kind of working conditions. On the current market, as the power and displacement of the plunger pump increase, its maximum power could reach 5000 hp and above, and the maximum displacement even reach over 3 m³/min. For satisfying the demands on large displacement and high pressure, the low pressure manifolds in the current conventional fracturing equipment actually employ 5″ of fluid feeding manifolds mostly. This kind of manifolds would induce empty circumstances due to insufficient liquid supply under large displacement working conditions, causing the vibration of the plunger pump and generating impact loads, thus affecting the life time of the plunger pump. At present, high pressure manifolds at home and abroad all use single-discharge plunger pumps, that is discharging fluid from one end of the plunger pump. This method has the following disadvantages: the plunger pumps used in the fracturing operations are usually five-cylinder plunger pumps, the high pressure fracturing fluid produced in the five cylinders could only be discharged from one discharging end, thus resulting in not smooth discharge of the fluid, causing circumstances such as sand accumulating within the low pressure manifold and the like.

Therefore, it is desirable to develop a manifold system of low pressure suction and high pressure discharge to meet the large displacement working conditions of the entire fracturing equipment.

SUMMARY

To overcome the deficiencies in the prior art, an objective of the present invention is to provide a manifold system of low pressure suction and high pressure discharge, in which the large displacement plunger pump is optimized from single-discharge to dual-discharge, overcoming the problems such as not smooth discharge of the fluid from the five-cylinder plunger pump, sand accumulating within the low pressure manifold, and the like; the 5″ fluid feeding manifold in the low pressure manifold is optimized to 10″ fluid feeding manifold, ensuring sufficient liquid supply under large displacement working conditions, thus avoiding the empty circumstances of the large displacement plunger pump, and providing a guarantee on the steady and smooth operations of the plunger pump.

The objective of the present invention is achieved by the following technical measures: a manifold system of low pressure suction and high pressure discharge, including a low pressure manifold, a high pressure manifold and a plunger pump, the low pressure manifold transports media into the hydraulic end of the plunger pump, the hydraulic end of the plunger pump is provided with two discharging ports, which are connected into the high pressure manifold.

Further, the plunger pump is a five-cylinder plunger pump.

Further, the power of the plunger pump is 5000 HP or above.

Further, the pipe diameter of the low pressure manifold is 10 inches or above.

Further, the low pressure manifold includes a suction manifold, a main manifold and connecting pipes, wherein the suction manifold is connected to one end of the main manifold, the connecting pipes are disposed on the main manifold, and the other ends of the connecting pipes are connected to the hydraulic end of the plunger pump.

Further, the pipe diameters of the suction manifold and the main manifold are both 10 inches or above.

Further, the suction manifold includes an union, a valve, an U-type tube and a connecting elbow, wherein one end of the U-type tube is connected to the union and the valve, and the other end of the U-type tube is connected to the main manifold through the connecting elbow.

Further, the valve is a butterfly valve.

Further, the main manifold includes a buffer and a main pipeline, wherein the buffer is disposed between the suction manifold and the connecting pipes, and the buffer is connected to the main pipeline.

Further, each connecting pipe is provided with a male union, and the output ends of the connecting pipes are connected to the hydraulic end of the plunger pump through the connecting flanges.

Further, the two discharging ports of the plunger pump are disposed on the horizontal both sides of the hydraulic end respectively.

Further, the high pressure manifold includes a manifold tee, a joint, a first elbow, a high pressure main pipe, a second elbow, a high pressure straight pipe and a third elbow, wherein the first port of the manifold tee is connected to one end of the high pressure main pipe, and the other end of the high pressure main pipe is connected to the third elbow, the third elbow is connected to the second elbow through the high pressure straight pipe, the second port of the manifold tee is connected to the first elbow through the joint, and the third port of the manifold tee is the output end.

Further, the two discharging ports of the plunger pump are connected to the high pressure manifold through the flange tee and the flange straight-through, respectively.

Further, the flange tee is connected to the first elbow, the flange straight-through is connected to the second elbow.

Compared with the prior art, the present invention has the following beneficial effects: the five-cylinder plunger pump of 5000 HP or above ensures the high pressure and large displacement power source for the fracturing equipment. The dual discharge form of the five-cylinder plunger pump achieves the smooth discharge of liquid from the five-cylinder plunger pump and prevents sand from accumulating within the low pressure manifold, meanwhile ensures the large displacement of the fracturing equipment. The low pressure manifold employs a large drift diameter manifold of 10 inches, with the double suction of an U-type tube to realize sufficient large displacement liquid supply from the five-cylinder plunger pump.

The present invention will be illustrated in detail below with reference to accompanying drawings and the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic structural diagram of the inventive manifold system.

FIG. 2 is a schematic structural diagram of the low pressure manifold.

FIG. 3 is a schematic structural diagram of the plunger pump.

FIG. 4 is a schematic structural diagram of the high pressure manifold.

FIG. 5 is a schematic structural diagram of the manifold tee.

Wherein, 1. low pressure manifold, 2. high pressure manifold, 3. plunger pump, 4. discharging port, 5. union, 6. butterfly valve, 7. U-type tube, 8. connecting elbow, 9. buffer, 10. main pipeline, 11. connecting pipe, 12. male union, 13. connecting flange, 14. manifold tee, 15. joint, 16. the first elbow, 17. high pressure main pipe, 18. the second elbow, 19. high pressure straight pipe, 20. the third elbow, 21. hydraulic end, 22. flange tee, 23. flange straight-through, 24. the first port, 25. the second port, and 26. the third port.

DESCRIPTION OF THE EMBODIMENTS

As shown in FIGS. 1 to 5, a manifold system of low pressure suction and high pressure discharge, including a low pressure manifold 1, a high pressure manifold 2 and a plunger pump 3, the low pressure manifold 1 transports media into the hydraulic end 21 of the plunger pump 3, the hydraulic end 21 of the plunger pump 3 is provided with two discharging ports 4, which are connected into the high pressure manifold 2. The dual discharge form of the five-cylinder plunger pump achieves the smooth discharge of liquid from the five-cylinder plunger pump and prevents sand from accumulating within the low pressure manifold 1, meanwhile ensures the large displacement of the fracturing equipment.

The plunger pump 3 is a five-cylinder plunger pump. The power of the plunger pump 3 is 5000 HP or above. The five-cylinder plunger pump at 5000 HP or above ensures the high pressure and large displacement power source for the fracturing equipment.

The pipe diameter of the low pressure manifold 1 is 10 inches or above.

The low pressure manifold 1 includes a suction manifold, a main manifold and connecting pipes 11, wherein the suction manifold is connected to one end of the main manifold, the connecting pipes 11 are disposed on the main manifold, and the other ends of the connecting pipes 11 are connected to the hydraulic end 21 of the plunger pump 3.

The pipe diameters of the suction manifold and the main manifold are both 10 inches or above. The low pressure manifold 1 employs a large drift diameter manifold of 10 inches to realize sufficient large displacement liquid supply from the five-cylinder plunger pump.

The suction manifold includes an union 5, a valve, an U-type tube 7 and a connecting elbow 8, wherein one end of the U-type tube 7 is connected to the union 5 and the valve, and the other end of the U-type tube 7 is connected to the main manifold through the connecting elbow 8. The double suction of the U-type tube 7 provides a guarantee on the sufficient large displacement liquid supply from the five-cylinder plunger pump.

The valve is a butterfly valve 6, which is used for the liquid supply on-off of the suction end of the low pressure manifold 1.

The main manifold includes a buffer 9 and a main pipeline 10, the buffer 9 is disposed between the suction manifold and the connecting pipes 11, and the buffer 9 is connected to the main pipeline 10.

Each connecting pipe 11 is provided with a male union 12, and the output ends of the connecting pipes 11 are connected to the hydraulic end 21 of the plunger pump 3 through the connecting flanges 13. The male union 12 is of 1·½ inches.

The two discharging ports 4 of the plunger pump 3 are disposed on the horizontal both sides of the hydraulic end 21 respectively, that is disposed at opposing positions of the two sides of the hydraulic end 21. The discharging ports 4 horizontally disposed on the two sides of the hydraulic end 21 could effectively ensure the smooth discharge of the hydraulic end 21 of the five-cylinder plunger pump, which is the prerequisite for realizing large displacement.

The high pressure manifold 2 includes a manifold tee 14, a joint 15, a first elbow 16, a high pressure main pipe 17, a second elbow 18, a high pressure straight pipe 19 and a third elbow 20, wherein the first port 24 of the manifold tee 14 is connected to one end of the high pressure main pipe 17, and the other end of the high pressure main pipe 17 is connected to the third elbow 20, the third elbow 20 is connected to the second elbow 18 through the high pressure straight pipe 19, the second port 25 of the manifold tee 14 is connected to the first elbow 16 through the joint 15, the third port 26 of the manifold tee 14 is the output end, and the manifold tee 14 is applicable to the high pressure manifold. The manifold tee 14 is a tee with a rotation angle of 45°. The opening of the 45° included angle of the manifold tee 14 faces towards the hydraulic end, that is, the opening orientation of the included angle is opposing with the discharging port on the other side of the plunger pump 3. Furthermore, the included angle formed between the first port 24 and the second port 25 of the manifold tee 14 is 45°, it is an obtuse-angle passageway of 135° between the second port 25 and the third port 26, while it is a linear passageway between the first port 24 connected to the other discharging port of the hydraulic end 21 and the third port 26, therefore ensuring the smooth discharge of high pressure media from the two discharging ports. At high pressure discharge, the first plunger pump 3 discharges through the discharging port at one side-the first elbow 16-the joint 15-the second port 25 of the manifold tee 14-the third port 26 of the manifold tee 14; and discharges through the discharging port at the other side-the second elbow 18-the high pressure straight pipe 19-the third elbow 20-the high pressure main pipe 17-the first port 24 of the manifold tee 14-the third port 26 of the manifold tee 14. The included angel of the joint 15 is 135°, the opening of which faces away from the hydraulic end. The opening angel and orientation of the joint 15 ensures the smooth and unimpeded discharge of high pressure media into the manifold tee 14.

The two discharging ports 4 of the plunger pump 3 are connected to the high pressure manifold 2 through the flange tee 22 and the flange straight-through 23, respectively.

The flange tee 22 is connected to the first elbow 16, and the flange straight-through 23 is connected to the second elbow 18.

It will be appreciated to persons skilled in the art that the present invention is not limited to the foregoing embodiments, which together with the context described in the specification are only used to illustrate the principle of the present invention. Various changes and improvements may be made to the present invention without departing from the spirit and scope of the present invention. All these changes and improvements shall fall within the protection scope of the present invention. The protection scope of the present invention is defined by the appended claims and equivalents thereof. 

1. A manifold system of low pressure suction and high pressure discharge, comprising a low pressure manifold, a high pressure manifold and a plunger pump, the low pressure manifold transports media into a hydraulic end of the plunger pump, the hydraulic end of the plunger pump is provided with two discharging ports, which are connected into the high pressure manifold, the pipe diameter of the low pressure manifold is at least 10 inches.
 2. The manifold system of low pressure suction and high pressure discharge according to claim 1, wherein the plunger pump is a quintuplex plunger pump.
 3. The manifold system of low pressure suction and high pressure discharge according to claim 1, wherein the power of the plunger pump is at least 5000 HP.
 4. (canceled)
 5. The manifold system of low pressure suction and high pressure discharge according to claim 4, wherein the low pressure manifold comprises a suction manifold, a main manifold and connecting pipes, wherein the suction manifold is connected to one end of the main manifold, the connecting pipes are disposed on the main manifold, and other ends of the connecting pipes are connected to the hydraulic end of the plunger pump.
 6. The manifold system of low pressure suction and high pressure discharge according to claim 5, wherein the pipe diameters of the suction manifold and the main manifold are both at least 10 inches.
 7. The manifold system of low pressure suction and high pressure discharge according to claim 4, wherein the suction manifold comprises a union, a valve, a U-type tube and a connecting elbow, wherein one end of the U-type tube is connected to the union and the valve, and the other end of the U-type tube is connected to the main manifold through the connecting elbow.
 8. The manifold system of low pressure suction and high pressure discharge according to claim 7, wherein the valve is a butterfly valve.
 9. The manifold system of low pressure suction and high pressure discharge according to claim 5, wherein the main manifold comprises a buffer and a main pipeline, wherein the buffer is disposed between a suction manifold and connecting pipes, and the buffer is connected to the main pipeline.
 10. The manifold system of low pressure suction and high pressure discharge according to claim 4, wherein each connecting pipe is provided with a male union, and output ends of the connecting pipes are connected to the hydraulic end of the plunger pump through connecting flanges.
 11. The manifold system of low pressure suction and high pressure discharge according to claim 1, wherein the two discharging ports of the plunger pump are disposed on a two separate horizontal ends of the hydraulic end respectively.
 12. The manifold system of low pressure suction and high pressure discharge according to claim 11, wherein the high pressure manifold comprises a manifold tee, a joint, a first elbow, a high pressure main pipe, a second elbow, a high pressure straight pipe and a third elbow, wherein a first port of the manifold tee is connected to one end of the high pressure main pipe, the other end of the high pressure main pipe is connected to the third elbow, the third elbow is connected to the second elbow through the high pressure straight pipe, a second port of the manifold tee is connected to the first elbow through the joint, and the third port of the manifold tee is the output end.
 13. The manifold system of low pressure suction and high pressure discharge according to claim 12, wherein the two discharging ports of the plunger pump are connected to the high pressure manifold through flange tees and flange straight-throughs, respectively.
 14. The manifold system of low pressure suction and high pressure discharge according to claim 13, wherein the flange tee is connected to the first elbow, the flange straight-through is connected to the second elbow. 